INSTALLATION
OVERVIEW of PROCEDURES
The Basic Installation Steps
Major Components
Specifications
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     The collector is most easily installed on a southerly* facing asphalt shingle roof, however, it can be installed in many situations, such as cedar shake, tile roofs and off orientation situations. The south-facing* roof must be free of shade for at least eight hours of the best available sun. A standard 18 degree tilt kit as well as custom tilt kits are available for orientation.

     A way must exist to run solar lines inside the house or garage from the attic to the  solar tank. The collector should be centered in such a way as to look balanced  between house features.

  THE BASIC INSTALLATION STEPS
                     (3 to 8 hours required to install, depending on situation and experience)

       1.Unpack collector, assemble the collector left and right sections into one unit as
          per pictures and instructions.

       2.Collector placement on roof located, rafters located and marked, end mounting
          rails with brackets lagged and sealed into rafters, collector placed into
          mounting rail brackets, center mounting rail and brackets placed, lagged and
          sealed into rafter, mounting rail brackets screwed into collector.

       3.Collector compression unions connecting air vent, pressure relief valve and
          components installed, two 1 1/2" holes drilled into roof for hot feed and cool
          return lines. Shingles trimmed and "Roof boots" installed under shingles and
          into holes.

       4.Collector cool feed (bottom compression union) and hot return lines (top
          compression union) installed through roof boots to tank area. Sensor, if used,
          installed in collector hot outlet, (or PV wire where used), connected and run to
          water heater area. Insulation partly installed before tubing connections are
          made. PV panel installed if used

       5.Water Heater Element or Gas turned off, water drained, lower drain removed,
          "Easy-Connect Assembly" installed, (or Thermosiphon Heat Exchanger, if
          used) collector cool feed (from circulator) and hot return lines connected by
          compression union.

       6.Water heater refilled, solar loop purged of air, pump plugged into timer (or PV
          wire or Differential Controller connected, where used). Air purged using return
          line hose bib, finish insulating lines, Element or Gas turned back on.
 

* - north facing in the southern hemisphere!

     COLLECTOR:

     The Fireball 2001 collector uses a high performance absorber coating with low emissivity and
     high absorbtivity for maximum performance. The inside walls of the collector feature a super high
     emissivity white coating to greatly reduce heat loss and reflect otherwise lost heat back onto the
     absorber. The unbreakable Lexan, "Twinwall" Glazing is very light weight. A unique and
     exceptionally strong mounting rail and sandwiched bracket system fully supports the width of the
     collector. The results are a high performance, ultra strong, ultra light weight and easy to install
     collector.

     GLAZING:

     The glazing or "window" to the collector takes the brunt of the harsh sun's rays and traps them
     inside to create a greenhouse effect similar to what is experienced when getting into a car with
     its windows closed on a sunny summer day. This glazing has an insulating effect that traps heat
     better than glass in cold weather. It is much lighter and will not break like glass. The glazing is 20
     square feet of a tough 6 mill (1/4") LEXAN double-walled polycarbonate material manufactured
     by General Electric (GE) with state of the art UV-protective acrylate surface treatment. It is factory
     guaranteed for 10 years.

     FRAME CONSTRUCTION:

     Designed to emulate a skylight in appearance and construction. The Patent Pending frame and
     trim is made out of Professionally finished bent 27 mil aluminum with ultra strong sandwiched
     mounting brackets. Special color keyed steel Hex screws and aluminum rivets are used as
     connectors. High quality 3/4" foil faced polyisocyanurate foam core insulation is used for the
     backboard.

     ABSORBER:

     The solar absorber, so called because it absorbs the sun's energy, is a proven all copper,
     "serpentine" design with the highest quality "selective surface" black absorber coating available.

     "QUICK CONNECT"
     TANK CONNECTION UNIT (System 1, 2, and 3):

     This high quality copper and brass unit allows for the quickest possible connection of the
     collector feed and return lines to the storage tank. This unit causes the existing "backup" tank to
     directly capture solar heated water. It is equipped with two shut off "isolation valves" to quickly
     close off the solar loop if needed or to allow the complete drainage of the solar loop for freeze
     protection through the two drain valves (hose bibs) mounted directly above the isolation valves.

     The solar circulator is mounted on the collector feed line directly above the hose bib. Two unions
     are included to allow easy shipping and assembly as well as a low point tank drain hose bib. On
     the roof, mounted at the outlet of the collector, is a safety pressure relief valve and an air vent to
     allow any trapped air to escape at the high point of the solar loop.

     A Passive "Thermal Freeze Valve" option is available for protection against freeze damage to
     the collector in open loop systems. This valve opens when temperatures go below 38o F (some
     valves are set to open at 45o) causing warmer water from the bottom of the storage tank to go
     through the collector. A check valve on the hot collector return side of the Quick Connect unit
     causes the flow of water to be mostly through the collector feed line and thus through all the
     collector tubes.

     OPTIONAL THERMOSIPHON HEAT EXCHANGER
     (System 4 and 5):

     This highly effective unit consists of a large vertically oriented waterside THERMOSIPHON loop
     copper tube. This tube is normally connected at the bottom of the water heater through the drain
     port and to the upper part of the tank through the pressure relief valve. A small amount of
     soldering is usually required to make this connection.

     Small "double walled" tubes go through the center of the larger waterside copper tube(s). These
     tubes are "double walled" to provide a double wall of protection against leakage of food grade
     "Propylene Glycol" (glycol) into the water (a highly unlikely event given that the water side is at a
     much higher pressure than the solar glycol side). The inner tubes are part of the completely
     separate solar loop and are heated by the flow of glycol pumped (and thus circulated) through the
     collector.

     A brass low point tank drain hose bib is also included. The "solar loop" is charged with food
     grade Propylene Glycol through two hose bibs, which have a check valve between them. A
     unique check valve prevents cooler glycol in the collector from causing a reverse flow of fluid at
     night from cooling the water heater. Included on the solar loop, mounted below the pump, is an
     "Expansion Tank" which is very important to allow for the expansion and contraction of the glycol
     in the closed solar loop. On the roof, mounted at the outlet of the collector, is a safety pressure
     relief valve and an air vent to allow any trapped air to escape at the high point of the solar loop.

     CIRCULATOR (PUMP):

     Standard high quality pumps are quiet, long life and low power consumption. 115V AC units
     come with built in line cord for easy connection to the control system. All Pumps are permanently
     oiled and do not need any service.

     The ultra reliable 12 Volt "ElSid" circulator has no moving motor parts, has a life expectancy of
     over 20 years and only needs a 5 or 10 watt PV panel depending on application. A high quality
     Hartell 12 Volt Electronic circulator is used for larger closed loop PV systems.

     CONNECTING LINES:

     The piping consists of 1/2" outside diameter (3/8" Nominal) soft copper plumbing tubes.
     Connections are made using standard brass compression unions. 50' of tubing is included with
     the kit.

     DIFFERENTIAL CONTROLLER
     (System 2 and 4):

     An electronic differential temperature control is designed specifically to regulate a solar system's
     operation. Its basic function is to monitor collector and storage temperatures and to automatically
     turn a circulation pump ON or OFF at the appropriate temperature differentials. Only the highest
     quality controllers are used.

     SENSORS:

     Two sensors perform the temperature sensing function. One is placed at the bottom of the solar
     heat exchanger tank, up against the outside of the core of tank. The other sensor is placed just
     inside the collector through the absorber hot out hole. The sensors are directly wired to the
     differential controller box.

     An optional freeze sensor attaches to the hot out line just as it leaves the collector box. This
     sensor closes at 40F for Recirculation freeze protection which is used extensively in mild weather
     conditions where temperatures occasionally dip below freezing (to as low as 20F for a few
     hours). It is thus is used for a higher level of Freeze Protection in light freeze areas than the
     Thermal freeze valve allows.

COLLECTOR (Panel)
Trim & Frame Materials: Finished 27 mil Aluminum Trim and Frame = Total 54 mil (1.37 mm).
Absorber Material:  Black coated copper or aluminum fin - all copper tubing with unions.
Glazing: .236" (6.0mm) Twinwall Polycarbonate UV Treated
Dimension / Weight:  Fireball 2001 - 144.3" x 20" x 3"; 38 lbs. (3.67 m x 0.51 m x 0.076 m 17.24 Kg) 18.4 Net s/f (1.71 m2)
Fluid Capacity:   .4 Gallons
Recommended Flow  Rates:  .20 to .35 GPM (0.946 to 1.324 L/min)
Maximum Working Pressure: 150 PSI (10.21 atm)
Maximum Stagnation Temp: 250 degrees F (121.11 degrees C)
Heat Transfer Fluid: Potable water or Propylene glycol
Standard Components: Mounting rails, mounting brackets, tech screws and lags
Optional colors.  Musket Brown (Cl01) standard

PUMP OR CIRCULATOR (standard) Type: 115 Volt AC Taco 006 Bronze or equal

PV POWERED PUMP (option) PV Panel: 5 Watt, 12volt DC or 10 Watt, 12volt DC
Circulator:  12 Volt - "El Sid", 12 Volt Hartell or equal.

FREEZE PROTECTION (Optional)
Type: Thermal Bleed Valve For light freeze protection  down to 30F
Temperature to open: 35 degrees F (1.66 degrees C). Starts to open and drip water at 38 degrees
Type:  Recirculation with 40F Freeze Snap Switch  For 110 Volt Differential Controller or with 12 Volt Circulator with  transformer for light freeze protection down to 20F.

CONNECTING LINES & INSULATION (standard)
Tubing: 1/2" (12.7 mm) OD copper - 50' (15.24 m)
Insulation [6' (1.83 m) supplied] 1/2" (12.7mm) ID 1/2" (12.7 mm) or 3/4" (19.05 mm) wall

TUBING CONNECTION METHODS (standard)
Type:  Brass Union, Compression (Solder for Thermosiphon to tank)

 STORAGE TANK (Not Supplied) Standard Connections:
Use Existing 50 gal (189.27 L) -- 120 gal (454.25 L) tank
Heat Exchanger Option: Existing 50 - 120 gal. with side pressure relief port, or 2nd tank with side connect  pressure relief port.   Max. Temp. - 190 degrees F (87.77 degrees C).   Max. Pressure - 150 psi (10.21 atm)

THERMOSIPHON HEAT EXCHANGER (option)
For use with standard circulator and differential control or with PV Option.
Type: Thermosyphon, double wall, 3' (.914 m) long, and 4' (1.22 m) for 4 collector systems.
Heat Exchanger Fluid: Propylene Glycol (Sierra)
Components:  Expansion Tank, two special check valves,  fill, drain and pressure relief valves

CONTROL (standard - non freeze application)
Type:  Heavy Duty 110v Timer w Ground
Type:  Optional: 12 Volt Circulator, 110F Snap Switch, 110 volt Transformer or PV Panel

DIFFERENTIAL CONTROL   DETAIL
  - Optional, for use with standard 110V circulator
 Required with heat exchanger using standard 110V circulator - 40F Freeze Snap switch for light freeze protection down to 20F -- optional on Del Sol)
Type:  Del Sol
Sensors:  Two Sensors with wire
Turn on Differential:  8 - 24 F (Avg. set 12 F)
Turn off Differential:   4 F (fixed)
Recirculate turn on:   38 F (3.33 C)
Storage High Limit: 110 - 230 F - Set at 180 F (82.2 C)
Power Requirements: 105 - 120VAC, 50/60hz,
Output power:  115VAC, 1/3HP (248.56 W)